FSM Shop Report
Content
PROJECT REPORT
By: Bhupender Singh Chugh Shop no. 2 at Pantnagar plant of Ashok Leyland is meant for the fabrication of frame side member (FSM) of the Heavy Load Trucks. Thin sheets ( Cold Rolled) of mild steel are used as raw material. The basic processes carried out in the manufacturing are as follows:
(a) Forming:
Thin sheets of MS are bent into U shape by using roll forming. Sheet is passed through a series of rolls to produce the required shape.
(b) Punching:
In this operation holes of various diameters are punched into the work piece using punching machine (sonam). The whole punching operation is carried out in a sound proof chamber using two CNC punching machines.
(c) Robotic plasma cutting:
Plasma cutting is a process which uses high velocity ionized gas, known as plasma, to heat and melt metals. The plasma then mechanically blows the molten material away to severe the work piece. Plasma cutting is used to cut steel or a non-ferrous material less than one inch thick. Robot plasma cutting is easy to use and offers higher quality cuts at faster travel speeds. This versatile application effectively cuts very thin & thick metals consistently.
ROBOTIC PLASMA CUTTING
(d) PICK AND PLACE PROCESSES
“Pick and Place” is a process of picking an object from one location and placing it at another location. These processes are commonly used in assembly lines Three pick and place processes were carried out: PP1- after robotic plasma cutting the work piece is transferred using electromagnetic hangers for machine washing PP2- after shot blasting process the work piece is transferred using hangers for pre treatment processes. Four work pieces can be transferred at a time. PP3-after all the pre treatment operations are performed, then the finished FSM is transferred for quality check.
(e) SHOT BLASTING
Shot blasting is a method used to clean, strengthen (peen) or polish metal. Shot blasting is used in almost every industry that uses metal, including aerospace, automotive, construction, foundry, shipbuilding, rail, and many others. There are two technologies used: wheel blasting or air blasting.
(i) Wheel blasting
Wheel blasting is basically abrasive blasting which directly converts electric motor energy into kinetic abrasive energy by rotating a turbine wheel. In this operation a stream of abrasive material is forcibly propelled against a surface under high pressure to smooth a rough surface, roughen a smooth surface, shape a surface, or remove surface contaminants. A pressurized fluid, typically air, or a centrifugal wheel is used to propel the blasting material .Abrasive, wheel blast machines are used where big parts or large areas of parts have to be de-rusted, de-scaled, de-burred, de-sanded or cleaned in some form.
(ii) Air blasting
Air blast machines can take the form of a blast room or a blast cabinet , the blast media is pneumatically accelerated by compressed air and projected by nozzles onto the component. For special applications a media-water mix can be used, this is called wet blasting. In both air and wet blasting the blast nozzles can be installed in fixed positions or can be operated manually. The blasting task determines the choice of the abrasive media, in most cases any type of dry or free running abrasive media can be used. The shot blasting operation performed in the shop is WHEEL BLASTING
PRE TREATMENT OPERATIONS
1) DEGREASING
Degreasing is done to remove the oil and dust layers that might be present on the surface of the blank.
2) WATER RINSE
The work piece is fed through a series of nozzles through which water with high velocity is forced on the surface to properly clean the surface.
3) ACTIVATION
Surface Activation activates the metal to obtain fine crystalline structure during phosphate coating which will increase corrosion resistance and adhesion properties. Crystalline structure less than 10 Microns is always preferable. If we are not using activation, the phosphate crystal size may be large and results in voids in Phosphate coating (Gap between structure will be large). Corrosion will take place at the voids.
4) PHOSPHATING
Phosphate coatings are used on steel parts for corrosion resistance, lubricity, or as a foundation for subsequent coatings or painting. It serves as a conversion coating in which a dilute solution of phosphoric acid and phosphate salts is applied via spraying or immersion and chemically reacts with the surface of the part being coated to form a [3] layer of insoluble, crystalline phosphates. Phosphate conversion coatings can also be used on aluminum, zinc, cadmium, silver and tin The performance of the phosphate coating is significantly dependent on the crystal structure as well as the weight. For example, a microcrystalline structure is usually optimal for corrosion resistance or subsequent painting. A coarse grain structure impregnated with oil, however, may be the most desirable for wear resistance. These factors are controlled by selecting the appropriate phosphate solution, using various additives, and controlling bath temperature, concentration, and phosphating time. Phosphate coating used here is of zinc phosphate basically meant for rust proofing.
5) PHOSPHATE WATER RINSE
Phosphate water rinse was performed using de- ionized water
SHOT BLASTING MACHINE
6) DRY OFF OVEN
In dry off oven the work piece is dried for about 10 minutes under the temperatures of about 90 to 100 degree Celsius to remove excess moisture.
7) DRY OFF COOLING
In dry off cooling the hot work piece from oven is air cooled slowly to room temperature. Slow cooling is done to prevent thermal stresses and cracking.
FRAME PAINTING
Frame painting is done to provide finish and make the surface corrosion resistant. The following processes takes place for painting of a Frame member.
1) POWDER COATING
Paint in the powdered form is given negative charge and is bombarded using an air pressurized (5-6 bar) electrode gun on the frame part having a positive charge. The charging is done to increase the adhesion between the two types of materials. 2) IR OVEN In IR oven Pre baking process is done where the powder coated part is heated to temperatures of about 120 C to wipe off any moisture content present and bring the powdered form to an almost molten state. 3) PC OVEN Then the part is finally baked in a PC baking oven at a temperature of 200 C for around 30-35 minutes 4) PC COOLING The blank is then slowly cooled to room temperature using air cooling by PC cooler.
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QUALITY CHECK
After the FSM is fully manufactured, various tests are performed on it to ensure the recommended quality. “dry film thickness” test is performed to ensure uniform powder coating on the FSM Test was performed to check for any gloss on the surface
REFERENCE- Wikipedia , staff members of FSM shop
By: Bhupender Singh Chugh Shop no. 2 at Pantnagar plant of Ashok Leyland is meant for the fabrication of frame side member (FSM) of the Heavy Load Trucks. Thin sheets ( Cold Rolled) of mild steel are used as raw material. The basic processes carried out in the manufacturing are as follows:
(a) Forming:
Thin sheets of MS are bent into U shape by using roll forming. Sheet is passed through a series of rolls to produce the required shape.
(b) Punching:
In this operation holes of various diameters are punched into the work piece using punching machine (sonam). The whole punching operation is carried out in a sound proof chamber using two CNC punching machines.
(c) Robotic plasma cutting:
Plasma cutting is a process which uses high velocity ionized gas, known as plasma, to heat and melt metals. The plasma then mechanically blows the molten material away to severe the work piece. Plasma cutting is used to cut steel or a non-ferrous material less than one inch thick. Robot plasma cutting is easy to use and offers higher quality cuts at faster travel speeds. This versatile application effectively cuts very thin & thick metals consistently.
ROBOTIC PLASMA CUTTING
(d) PICK AND PLACE PROCESSES
“Pick and Place” is a process of picking an object from one location and placing it at another location. These processes are commonly used in assembly lines Three pick and place processes were carried out: PP1- after robotic plasma cutting the work piece is transferred using electromagnetic hangers for machine washing PP2- after shot blasting process the work piece is transferred using hangers for pre treatment processes. Four work pieces can be transferred at a time. PP3-after all the pre treatment operations are performed, then the finished FSM is transferred for quality check.
(e) SHOT BLASTING
Shot blasting is a method used to clean, strengthen (peen) or polish metal. Shot blasting is used in almost every industry that uses metal, including aerospace, automotive, construction, foundry, shipbuilding, rail, and many others. There are two technologies used: wheel blasting or air blasting.
(i) Wheel blasting
Wheel blasting is basically abrasive blasting which directly converts electric motor energy into kinetic abrasive energy by rotating a turbine wheel. In this operation a stream of abrasive material is forcibly propelled against a surface under high pressure to smooth a rough surface, roughen a smooth surface, shape a surface, or remove surface contaminants. A pressurized fluid, typically air, or a centrifugal wheel is used to propel the blasting material .Abrasive, wheel blast machines are used where big parts or large areas of parts have to be de-rusted, de-scaled, de-burred, de-sanded or cleaned in some form.
(ii) Air blasting
Air blast machines can take the form of a blast room or a blast cabinet , the blast media is pneumatically accelerated by compressed air and projected by nozzles onto the component. For special applications a media-water mix can be used, this is called wet blasting. In both air and wet blasting the blast nozzles can be installed in fixed positions or can be operated manually. The blasting task determines the choice of the abrasive media, in most cases any type of dry or free running abrasive media can be used. The shot blasting operation performed in the shop is WHEEL BLASTING
PRE TREATMENT OPERATIONS
1) DEGREASING
Degreasing is done to remove the oil and dust layers that might be present on the surface of the blank.
2) WATER RINSE
The work piece is fed through a series of nozzles through which water with high velocity is forced on the surface to properly clean the surface.
3) ACTIVATION
Surface Activation activates the metal to obtain fine crystalline structure during phosphate coating which will increase corrosion resistance and adhesion properties. Crystalline structure less than 10 Microns is always preferable. If we are not using activation, the phosphate crystal size may be large and results in voids in Phosphate coating (Gap between structure will be large). Corrosion will take place at the voids.
4) PHOSPHATING
Phosphate coatings are used on steel parts for corrosion resistance, lubricity, or as a foundation for subsequent coatings or painting. It serves as a conversion coating in which a dilute solution of phosphoric acid and phosphate salts is applied via spraying or immersion and chemically reacts with the surface of the part being coated to form a [3] layer of insoluble, crystalline phosphates. Phosphate conversion coatings can also be used on aluminum, zinc, cadmium, silver and tin The performance of the phosphate coating is significantly dependent on the crystal structure as well as the weight. For example, a microcrystalline structure is usually optimal for corrosion resistance or subsequent painting. A coarse grain structure impregnated with oil, however, may be the most desirable for wear resistance. These factors are controlled by selecting the appropriate phosphate solution, using various additives, and controlling bath temperature, concentration, and phosphating time. Phosphate coating used here is of zinc phosphate basically meant for rust proofing.
5) PHOSPHATE WATER RINSE
Phosphate water rinse was performed using de- ionized water
SHOT BLASTING MACHINE
6) DRY OFF OVEN
In dry off oven the work piece is dried for about 10 minutes under the temperatures of about 90 to 100 degree Celsius to remove excess moisture.
7) DRY OFF COOLING
In dry off cooling the hot work piece from oven is air cooled slowly to room temperature. Slow cooling is done to prevent thermal stresses and cracking.
FRAME PAINTING
Frame painting is done to provide finish and make the surface corrosion resistant. The following processes takes place for painting of a Frame member.
1) POWDER COATING
Paint in the powdered form is given negative charge and is bombarded using an air pressurized (5-6 bar) electrode gun on the frame part having a positive charge. The charging is done to increase the adhesion between the two types of materials. 2) IR OVEN In IR oven Pre baking process is done where the powder coated part is heated to temperatures of about 120 C to wipe off any moisture content present and bring the powdered form to an almost molten state. 3) PC OVEN Then the part is finally baked in a PC baking oven at a temperature of 200 C for around 30-35 minutes 4) PC COOLING The blank is then slowly cooled to room temperature using air cooling by PC cooler.
o o
QUALITY CHECK
After the FSM is fully manufactured, various tests are performed on it to ensure the recommended quality. “dry film thickness” test is performed to ensure uniform powder coating on the FSM Test was performed to check for any gloss on the surface
REFERENCE- Wikipedia , staff members of FSM shop
